The resurrection of my 1960 karmann ghia

[crystallographic]

Nice looking progress, Antoine. Steady and patient, and going into the blue is great as you are now turning the corner upwards.

[Antoine_P]

Thanks both of you for the support!

So, that was the next logical step (just had to wait as I am finishing my beetle engine and putting it back on the road ).. welder was again put in use!!

Last adjustment:


And welded:


Ground down:


And in primer:


It is so satisfying seeing this step finished!

And as I was there, also finished that corner:


Made the patch:




And welded:


One day it will sit here:


But first I will weld it back here:


Cheers

Antoine

[crystallographic]

Originally Posted by Antoine_P

Thanks both of you for the support!

So, that was the next logical step (just had to wait as I am finishing my beetle engine and putting it back on the road ).. welder was again put in use!!

Last adjustment:


And welded:


Ground down:


And in primer:


It is so satisfying seeing this step finished!

And as I was there, also finished that corner:


Made the patch:




And welded:


One day it will sit here:


But first I will weld it back here:


Cheers

Antoine

I am enjoying your repair story very much, Antoine.
Patient, thoughtful, energetic practice ... and a very nice K-Ghia will result, giving countless joyful motoring hours.

And economical - as a woman told me years ago, after buying one new : "42 MPG! - at 70mph. I love this car!"

[cliffrod]

Always like to see your work and progress, Antoine. I've got my old 1962 Triumph TR3, patiently waiting for lots of similar work. Following your project thread is helping me think and plan. Hopefully it will go as well as your Ghia rebuild. Thanks for keeping us updated.

[Antoine_P]

Thanks a lot for the support guys! Still having issue with my beetle's engine, can't wait for it to be finished and start again 100% on the ghia!

But in the meanwhile I still did manage to do more on it
There was still one last step to finish the right wheel well:


Yes, this bottom part was pretty rusted out so time for it to go..preparing the replacement:


under it wasn't better either:


all cut:


I changed the wheel well metal and the new heater channel will then be welded on it. So let's take the TIG out :




and fully replaced:






and in primer:




Feels so good seeing the progress here:


stay tuned for a next update soon!

Antoine

[Antoine_P]

So, still doing some progress on that project

After finishing the right side, I started on the left.

First checking/adjusting the parts I made for the left airbox:








And then removed the old rusted airbox:


Under it.. well some holes




So I started checking the replacement panel:


As for the other side, the top curve doesn’t fit:




So I corrected it:



And also made the hole for the wiring:








Then marked how big this panel is:



And where I should cut to remove all the rust but keep the original indent:


Then.. cut!



And putting the panel to cut it precisely, cut and adjusted for welding:


Sadly I then discovered that my argon bottle is empty.. so welding next time!

I also prepared the next steps by grinding down the old welding points:


Cheers

Antoine

[Moving Molecules .]

Hi , I worked for a so called Karmann Ghia specialist here in the UK ( only job I’ve walked out of ! ) so know my way around this model easily...
We are restoring a very rare 58 Lowlight....... convertible....

They are very well built and measure up well but they did badly Rust.... Like the Volvo P 1800....

If you need any help... Precision panel Craft UK.

Cheers Matt....

[DavidR8]

Antoine, I was referred to your thread from another site.
First, let me say that I'm so impressed with the job you're doing.
Years back I owned a '65 Ghia that was in much the same condition as yours. I did not have the skills, time or space to attempt anything even close to what you are doing. I still don't have the skills to make much more than a bracket
Good on you for diving in!

[Moving Molecules .]

Don’t forget to put your rubber trim on the front edge of the inner wing !.... as per factory it should have overspray on it.

[Antoine_P]

Thanks a lot guys!

Matt: thanks for the advice, I will mount them before paint!

David: Thanks a lot!! I am curious where did you get the recommandation : but happy you enjoy this project

So, I finished welding my panel after picking up a new bottle of Argon:




And after planishing:




I also continued the front axle assembly:




Putting grease wherever needed:




And started cleaning the 60 only gearbox:
-before:


-Current Status:




Cheers

Antoine